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Low qualified rate and inferior quality frequently occurring in the general deep drawing process of a certain box-shaped part, now use hydroforming to optimize forming process, in order to study the effect of hydroforming for improving the quality and formability, purposed five process schemes: general deep drawing, active hydroforming, passive hydroforming, general deep drawing combined with active hydroforming, passive combined with active hydroforming. Each process was simulated by finite element simulation and results were analysed. The results indicate the passive combined with active hydroforming is the best scheme which can obtain smallest thickness thinning and satisfactory formability, then optimized hydroforming pressure, blank holder force subsequently by adjust the simulation parameters. Research result proves that active/passive hydroforming is a new method for complex parts forming.

Numerical simulation study on active and passive hydroforming process optimization of box shaped part